Mesoporous material with active metals

ABSTRACT

A process for treating organic compounds includes providing a composition which includes a substantially mesoporous structure of silica containing at least 97% by volume of pores having a pore size ranging from about 15 Å to about 30 Å and having a micropore volume of at least about 0.01 cc/g, wherein the mesoporous structure has incorporated therewith at least about 0.02% by weight of at least one catalytically and/or chemically active heteroatom selected from the group consisting of Al, Ti, V, Cr, Zn, Fe, Sn, Mo, Ga, Ni, Co, In, Zr, Mn, Cu, Mg, Pd, Pt and W, and the catalyst has an X-ray diffraction pattern with one peak at 0.3° to about 3.5° at 2θ. The catalyst is contacted with an organic feed under reaction conditions wherein the treating process is selected from alkylation, acylation, oligomerization, selective oxidation, hydrotreating, isomerization, demetalation, catalytic dewaxing, hydroxylation, hydrogenation, ammoximation, isomerization, dehydrogenation, cracking and adsorption.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation in part of U.S. applicationSer. No. 09/995,227 filed Nov. 27, 2001 and incorporated by referenceherein, which is a continuation in part of U.S. application Ser. No.09/390,276 filed Sep. 7, 1999, now issued as U.S. Pat. No. 6,358,486 B1,to which priority is claimed.

BACKGROUND

1. Field of the Invention

The present invention relates to a mesoporous material, particularly acatalytic material, and use of the mesoporous material for theconversion of organic compounds, particularly hydrocarbons.

2. Background of the Prior Art

Most of today's hydrocarbon processing technologies are based on zeolitecatalysts. Zeolite catalysts are well known in the art and possesswell-arranged pore systems with uniform pore sizes. However, thesematerials tend to possess either only micropores or only mesopores.Micropores are defined as pores having a diameter less than about 2 nm.Mesopores are defined as pores having a diameter ranging from about 2 nmto about 50 nm.

Because such hydrocarbon processing reactions are mass-transfer limited,a catalyst with an ideal pore size will facilitate transport of thereactants to active catalyst sites and transport the products out of thecatalyst.

There is yet need for an improved material having functionalized siteswithin a porous framework for processes directed to the catalyticconversion and/or adsorption of hydrocarbons and other organiccompounds.

SUMMARY OF THE INVENTION

A process for treating organic compounds is provided herein. The processcomprises: (a) providing a composition which includes a substantiallymesoporous structure of silica containing at least 97% by volume ofpores having a pore size ranging from about 15 Å to about 30 Å andhaving a micropore volume of at least about 0.01 cc/g, wherein themesoporous structure has incorporated therewith at least about 0.02% byweight of catalytically and/or chemically active heteroatoms selectedfrom the group consisting of Al, Ti, V, Cr, Zn, Fe, Sn, Mo, Ga, Ni, Co,In, Zr, Mn, Cu, Mg, Pd, Pt and W, and wherein said catalyst has an X-raydiffraction pattern with one peak at 0.3° to about 3.5° at 2θ; and, (b)contacting an organic feed under reaction conditions with said catalystwherein the treating process is selected from the group consisting ofalkylation, acylation, oligomerization, selective oxidation,hydrotreating, isomerization, demetalation, catalytic dewaxing,hydroxylation, hydrogenation, ammoximation, isomerization,dehydrogenation, cracking and adsorption.

One aspect of this invention deals with an improved catalytic processfor the demetalation and desulfurization of petroleum oils, preferablythose residual fractions with undesirably high metals and/or sulfurand/or nitrogen contents and/or Conradson Carbon Residue (CCR). Moreparticularly, this invention relates to a hydrotreating process forreducing high metals, sulfur and nitrogen contents and CCR of petroleumoils, again preferably those containing residual hydrocarbon components.

Residual petroleum oil fractions are produced by atmospheric or vacuumdistillation of crude petroleum; they generally contain high amounts ofmetals, sulfur, nitrogen and CCR content. This comes about becausepractically all of the metals and CCR present in the original cruderemain in the residual fraction, and a disproportionate amount of sulfurand nitrogen in the original crude oil also remains in that fraction.Principal metal contaminants are nickel and vanadium, with iron andsmall amounts of copper also sometimes present.

The high metals, sulfur, nitrogen, and CCR content of the residualfractions generally limit their effective use as charge stocks forsubsequent catalyst processing such as catalytic cracking andhydrocracking. The metal contaminants deposit on the special catalystsfor these cracking processes and cause the premature aging of thecatalyst and/or unwanted side reactions such as cracking to coke, drygas and hydrogen. During the FCC process, much of the sulfur ends up inthe FCC catalyst's coke, which is burned during regeneration, resultingin substantial SOx emissions. Another major fate of the residua's sulfuris in the final cracked products, such as gasoline and light cycle oil(a blending component for diesel fuel and home heating fuel). Some ofthe nitrogen contributes to NOx emissions, and some nitrogen (the basicnitrogen compounds) becomes bound to the active sites of the FCCcatalyst and renders it ineffective. CCR, a measure of a molecule'stendency to coke rather than crack and/or distill, is also anundesirable property for charge streams processed by catalytic cracking.Under the high temperature employed in catalytic cracking, moleculeshigh in CCR thermally and/or catalytically degrade to coke, light gases,and hydrogen. Catalytic cracking is generally done utilizing hydrocarboncharge stocks lighter than residual fractions, which generally have anAPI gravity less than 20. The most common, cracking charge stocks arecoker and/or crude unit gas oils, vacuum tower overheads, etc., thefeedstock having an API gravity from about 15 to about 45. Since thesecracking charge stocks are distillates, they do not contain significantproportions of the large molecules in which the metals are concentrated.Such cracking is commonly carried out in a reactor operated at atemperature of about 425 to 800° C., a pressure of about 1 to 5atmospheres, and a space velocity of about 1 to 1000 WHSV.

Metals and sulfur contaminants would present similar problems inhydrocracking operations that are typically carried out on charge stockseven lighter than those charged to a cracking unit. Typicalhydrocracking reactor conditions consist of a temperature of 200 to 550°C. and a pressure of 700 to 20,000 kPa.

It is evident that there is considerable need for an efficient method toreduce the metals and/or sulfur and/or nitrogen and/or CCR content ofhydrocarbons, and particularly of residual petroleum fractions. Whilethe technology to accomplish this for distillate fractions has beenadvanced considerably, attempts to apply this technology to residualfractions generally fail due to very rapid deactivation of the catalyst,primarily by metals contaminants and coke deposition.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments are described below with reference to the drawingswherein:

FIG. 1 is an X-ray diffraction pattern (“XRD”) of the mesoporousmaterial of Example 1;

FIG. 2 is a transmission electron microscopy (“TEM”) image of themesoporous material of Example 1;

FIG. 3 is a graph illustrating the pore size distribution of themesoporous material of Example 1;

FIG. 4 is an XRD pattern of the mesoporous material of Example 2;

FIG. 5 shows the XRD patterns of the mesoporous materials of Examples3A, 3B and 3C;

FIG. 6 is a graph illustrating the pore size distribution of themesoporous material of Example 3A;

FIG. 7 is an XRD pattern of the vanadium-containing mesoporous materialof Example 5;

FIG. 8 is an XRD pattern of the titanium-containing mesoporous materialof Example 6;

FIG. 9 is a graph illustrating the nitrogen sorption isotherms of thetitanium-containing mesoporous material of Example 6;

FIG. 10 is a graph illustrating the pore size distribution of thetitanium-containing mesoporous material of Example 6;

FIG. 11 shows the XRD patterns of the mesoporous materials of Examples7, 8, and 9;

FIG. 12 is an XRD pattern of the aluminum and vanadium-containingmesoporous material of Example 10;

FIG. 13 is a graph illustrating the pore size distribution of thealuminum and vanadium-containing mesoporous material of Example 10;

FIG. 14 is an XRD pattern of the iron-containing mesoporous material ofExample 11;

FIG. 15 shows the UV-Visible spectrum of the iron-containing mesoporousmaterial of Example 11;

FIG. 16 is a graph showing the pore size distribution of theiron-containing mesoporous material of Example 11;

FIG. 17 is an XRD pattern of the chromium-containing mesoporous materialof Example 13;

FIG. 18 shows the UV-Visible spectrum of the chromium-containingmesoporous material of Example 13;

FIG. 19 is a graph showing the mesopore size distribution of themesoporous material of Example 13;

FIG. 20 is an XRD pattern of the molybdenum-containing mesoporousmaterial of Example 15;

FIG. 21 shows the UV-Visible spectrum of the mesoporous material ofExample 15; and,

FIG. 22 is a graph showing the mesopore size distribution of themesoporous material of Example 15.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S)

The catalyst of the present invention includes a three-dimensional,stable, porous silica, which is substantially mesoporous in structure.The silica possesses a non-crystalline, but regularized(pseudo-crystalline) structure. Mesoporous materials are described inU.S. Pat. No. 6,358,486 B1, which is herein incorporated by reference inits entirety.

The amorphous silica material of the present invention generallycontains both mesopores and micropores. Micropores are defined as poreshaving a diameter of less than about 2 nm. Mesopores are defined aspores having a diameter of from about 2 nm to about 50 nm. The inorganicoxide material of the present invention has a volume percentage ofmesopores of at least about 97% and preferably at least about 98%.

A method for making a preferred porous silica-containing catalystsupport is described in U.S. Pat. No. 6,358,486 B1. The average mesoporesize of the preferred catalyst as determined from N₂-porosimetry rangesfrom about 2 nm to about 25 nm.

The catalyst includes, and is functionalized with, one or morecatalytically active metal heteroatoms incorporated into the poroussilicate structure. The catalytically active metal heteroatom (i.e.,non-silicon atom) can be selected from Groups IB, IIB, IIIB, IVB, VB,VIIB, VIIB, VIII, IVA, and IIIA of the Periodic Table of the Elements.Suitable metal heteroatoms include aluminum (Al), titanium (Ti),vanadium (V), chromium (Cr), zinc (Zn), iron (Fe), tin (Sn), molybdenum(Mo), gallium (Ga), nickel (Ni), cobalt (Co), indium (In), zirconium(Zr), manganese (Mn), copper (Cu), magnesium (Mg), palladium (Pd),platinum (Pt) and tungsten (W), for example. The incorporatedheteroatoms can be isolated and/or distributed as clusters in the porousmatrix. They can be in an atomic form or molecular form (e.g., asoxide). The heteroatom content of the catalyst is at least about 0.02%by weight of the catalyst. The atomic ratio of the heteroatoms tosilicon atoms in the catalyst can be varied up to about 0.9, preferablyfrom about 0.0001 to about 0.5.

The composition of the present invention has a characteristic X-raydiffraction pattern (“XRD”) which shows at least one peak at 0.3° to3.5° at 2θ, which corresponds to a basal spacing between 25 Å and 440 Å.Nitrogen adsorption tests reveal a tunable pore size ranging from about15 Å (1.5 nm) to about 300 Å (30 nm), and a surface area ranging fromabout 300 m²/g to about 1,250 m²/g, and a pore volume of from about 0.3cc/g to about 2.5 cc/g.

The composition of the present invention has a three-dimensional,randomly connected mesopore system, which facilitates mass-transfer ofreactants and products, and avoids pore blockage.

Generally, the mesoporous silica material of the present invention isprepared from a synthesis mixture containing at least one silica source,at least one heteroatom source, and at least one pore-forming organictemplating agent.

In a first stage of the method for making the catalyst of the invention,the silica source, heteroatom source, and organic templating agent(s)are combined in aqueous solution to form a synthesis mixture (usually agel).

In an intermediate stage of the method, the volatile components of thesynthesis mixture (e.g., water, alcohol) are removed by conventionalmeans such as drying with or without forced air flow. The drying can beconducted, for example, at 40° C. to about 130° C. for up to about 72hours, more preferably from about 60° C. to about 120° C. for 6 to 36hours.

In a final stage the organic templating agent(s) are removed byconventional means such as calcining and extraction. Typically, thecalcining is performed at a temperature of from about 450° C. to about900° C. with an oxygen-containing gas (e.g., air) for 2 to 20 hours,preferably at 540° C. to about 700° C. for about 4 to 15 hours. Theextraction can be done using organic solvents at a temperature of fromabout 30° C. to about 1001C, depending upon the solvent used. Somealcohols with low or no toxicity are preferable as solvents.

Optionally, the method can include aging the synthesis mixture at 10° C.for up to 24 hours before removing the volatile components of thesynthesis mixture.

Optionally, the synthesis mixture can be heated in an autoclave at atemperature of from about 100° C. to about 220° C. for up to about 10days, preferably at a temperature of from about 120° C. to about 200° C.for up to 96 hours, before removing the pore forming agent. The heatingstep in the autoclave can tune the mesoporosity to meet specificrequirements. During the heating, inorganic species such as silicon andaluminum will coalesce to form an inorganic framework, while the poreforming agent forms aggregates to shape the inorganic framework. Thesize distribution of the aggregates determines the mesopore sizedistribution. However, the aggregate size mainly depends on the natureof the pore forming agent, the temperature of heating and the length ofthe heating time. So for a certain pore-forming agent, the mesoporosityof the final material can be tuned by manipulating the temperature andthe heating time.

More particularly, in the first stage, the silica source, or silicaprecursor, can be a silicon compound containing some organic groups.Such compounds can be alkoxides, e.g., tetraethyl orthosilicate(“TEOS”), and silatranes, e.g., triethanolamine-substituted silatranes.The silica source can alternatively be inorganic, such as anhydrous orhydrous silica gels or silica hydrogels. The silica source also can begeothermal silica, but to facilitate reactivity, is preferably not acrystalline source.

The organic templating agent preferably contains hydroxyl (—OH) groupsthat form hydrogen bonds with the inorganic species (i.e., silica andheteroatom). They may have atoms with a pair of electrons that can bondwith the silicon or heteroatoms. Such organic templating agents includeglycols (e.g., propylene glycol, glycerol, diethylene glycol,triethylene glycol, tetraethylene glycol), alkanolamines (e.g.,triethanolamine [“TEA”], triisopropanolamine), diethylglycol dibenzoate,triethylene pentamine, starch, and sulfolane. The organic templatingagent should have a boiling point above 150° C., preferably above about180° C.

The heteroatom source can be with or without organic groups and istypically added in the form of a solution. For example, in the case ofaluminum, the source can be aluminum alkoxide (e.g., aluminumisopropoxide), alumina, aluminum hydroxide, aluminum nitrate, aluminumsulfate, or aluminum chloride.

The synthesis mixture can also include alkali or acid to adjust the pHof the mixture. Alkalis typically include organic alkali such astetraethylammonium hydroxide (“TEAOH”) and other tetraalkylammoniumhydroxides, urea, and the like, or inorganic alkali such as ammoniumhydroxide, sodium hydroxide, sodium carbonate, and the like.

The solvents, reaction conditions, the order of adding and mixingcomponents and the pH can depend upon the heteroatom and should beselected to avoid premature separation (e.g., precipitation) of theheteroatom. Premature separation can result in failure of the heteroatomto be incorporated into the silica structure.

The composition of the invention can be applied as catalysts,co-catalysts (a part of catalysts), catalyst supports, adsorbents andmolecular sieves. Depending on the functionality of the incorporatedheteroatoms, the composition can have weak, medium and strong acidity,consequently it can catalyze cracking, isomerization, alkylation,acylation, oligomerization/polymerization, dehydration of organiccompounds and desulfurization. The composition can also have redoxproperties, which can catalyze epoxidation of alkenes (e.g.,cyclohexene, octene, ethylene, or propylene), selective oxidation ofalkanes (e.g. cyclododecane, cyclohexane), alcohols and amines,hydroxylation of aromatics and ammoximation of ketones. The compositioncan be used as co-catalysts or catalyst supports. For instance, additionof noble metals, e.g. Pd and/or Pt/to this composition offersfunctionality of hydrocracking, hydrogenation, dehydrogenation, anddesulfurization. This composition can also contain all types of zeolitesand zeolite-like structures, together with all possible heteroatomsmentioned above.

A typical example of the composition of the invention, which offersacidity, is the one containing aluminum and/or gallium. A group ofindustrially important reactions is alkylation, which conventionallyuses corrosive Lewis acids such as AlCl₃ and HF and generates largeamount of wastes. The composition of this invention is environmentalfriendly and can replace the conventional catalysts. It can catalyzealkane or aromatic alkylation (including Friedel-Crafts alkylation)using olefins, alkyl halides or alcohols as alkylation agents. Thearomatic compounds mainly include benzene, naphthalene, phenanthrene andtheir derivatives, such as toluene, xylene, isopropylnaphthalene,di-phenyl oxide, or 2,4-di-t-butylphenol. The olefin alkylation agentsmainly include alpha-olefins, preferably those with a carbon number morethan two, preferably more than four. Suitable olefins include e.g.,ethylene, propylene, and 1-hexadecene. Alcohol alkylation agents mainlyinclude methanol, ethanol, isopropanol, benzyl alcohol, and cinnamylalcohol. The alkylation reaction can be carried out at a temperature offrom about 80° C. to about 400° C., under a pressure between 1 and 50bars, preferably from about 90° C. to about 300° C. and between 1 and 30bars.

Oligomerization and polymerization of olefins can produce fractions forgasoline, jet fuel, diesel fuel and lubricating base oil. The catalystcomposition of the invention, especially those containing aluminum,chromium, gallium or iron heteroatoms, can be used as catalysts foroligomerization of olefins such as alpha-olefins with a carbon numberlarger greater than three. Reaction conditions, depending on thespecific feedstocks and desired products, include a temperature rangingfrom about 25° C. to about 300° C., and a pressure ranging fromatmospheric pressure to about 70 bars.

The catalyst composition of the invention can be used for the selectiveoxidation of organic compounds. Particularly preferred are thosecatalyst compositions containing one or more heteroatoms selected fromtransition metals including, for example, copper, zinc, iron, titanium,chromium, vanadium, molybdenum and tin. For instance, the compositioncontaining titanium, zinc, chromium, iron and manganese can catalyzeepoxidation of olefins including aromatics such as phenanthrene,anthracene and trans-stilbene. The oxidants used in this type ofreaction include organic or inorganic peroxides, nitrogen oxides, oxygenand any gas mixture containing oxygen. The composition containing copperand zinc is particularly preferred for catalyzing the selectiveoxidation of alcohols to corresponding aldehydes. Hydroxylation ofphenol and 1-naphthol can be accomplished using the catalyst compositioncontaining tin, iron, copper, cobalt and vanadium.

In the prior art, acylation of aromatics was conventionally performedusing Lewis acids, such as AlCl₃, FeCl₃, H₂SO₄, etc. which generated ahuge amount of wastes. In contrast, the composition of the presentinvention, especially embodiments that contain aluminum, iron, gallium,indium, etc., replaces the Lewis acids. Acylation agents mainly includeacyl halide, carboxyl acid anhydride. The aromatic compounds mainlyinclude benzene, naphthalene, phenanthrene and their derivatives.Acylation can be carried out at a temperature from about 40° C. to about300° C., under a pressure of from about 0.5 bar to about 20 bars,preferably from about 60° C. to about 250° C., and a pressure of fromabout 1 to 15 bars.

When incorporated as heteroatoms in the mesoporous silica of theinvention, transition metals such as cobalt, nickel, molybdenum,tungsten, or combinations thereof, or noble metals such as platinum,palladium or combinations thereof, provide catalysts particularlysuitable for hydrotreating process such as (1) hydrogenation ofaromatics in gasoline, jet fuel, diesel fuel and lubricating oil; (2)hydrocracking of heavy fractions such as vacuum gas oil, residuumfractions and liquids derived from coal (coal oil); (3) CCR reduction,denitrogenation, desulfurization, and demetalation of hydrocarbons,including the above-mentioned fractions. Demetalation is particularlyuseful for the removal of iron, nickel, vanadium, and arsenic.Hydrotreating reaction conditions typically include a reactiontemperature ranging from about 40° C. to about 400° C., preferably fromabout 60° C. to about 350° C., and a pressure ranging from atmosphericpressure to about 300 bars.

Isomerization of hydrocarbons (e.g. n-butane, n-pentane, 1-butene andxylene) can be catalyzed by using the catalyst of the invention.Preferred catalyst compositions for isomerization contain zirconium,tungsten, gallium, iron, titanium and aluminum as heteroatoms.

Dehydrogenation of saturated hydrocarbons to unsaturated hydrocarbonscan be catalyzed using the composition containing mainly vanadium, iron,gallium, cobalt and chromium. The saturated hydrocarbon can be, forexample, propane, isobutane and ethylbenzene. The gas hourly spacevelocity (GHSV) normally ranges from 100 to 2000 hr⁻¹, preferably from500 to 1000 hr⁻¹. The operating pressure normally ranges from about 7kPa to about 600 kPa, preferably from about 7 kPa to about 400 kPa. Thereaction temperature typically ranges from about 350° C. to about 650°C., preferably from about 450° C. to about 600° C.

Hydrocarbon cracking can advantageously be carried out using theinventive catalyst composition containing nickel, tungsten, cobalt,molybdenum, aluminum and/or gallium. Moreover, the catalyst compositionof the invention can be used alone or together with zeolites. Thehydrocarbon can be feedstock for fluid catalytic cracking,hydrocracking, etc. The catalyst composition can also catalyze thecracking of waste polymers to recover useful fractions of desirablechemicals.

The composition can be used as a catalyst for Fischer-Tropsch process.The process involves contacting a feed stream comprising hydrogen andcarbon monoxide with the catalyst in a reaction zone maintained atconversion-promoting conditions effective to produce an effluent streamcomprising hydrocarbons. The gas hourly space velocity (GHSV) may rangefrom about 100 volumes/hour/volume catalyst (hr⁻¹) to about 10,000 hr⁻¹,preferably from about 300 hr⁻¹ to about 2,000 hr⁻¹. The reactiontemperature is typically in the range from about 160° C. to about 300°C., preferably from about 190° C. to about 260° C. The reaction pressureis typically in the range of about 5 bar to about 60 bar, preferablyfrom 8 bar to about 30 bar.

The composition can be used to effectively and selectively adsorbparticular compounds. Due to its tunable pores and functionalized porewall, it allows various compounds to enter the pores and interact withfunctional heteroatom groups on or in the wall. For instance, theincorporated heteroatoms can have high but unsaturated coordinationnumbers, which enables the heteroatoms to form coordination bonds withoxygen-containing, nitrogen-containing, and sulfur-containing compounds,thereby effectively removing these compounds from streams. It can alsobe a base-acid interaction. For example, the composition containingaluminum can remove toxic compounds such as cyanuric acid andp-chlorophenol from streams. As such, the composition can be used asadsorbents and molecular sieves.

The invention disclosure presents a new type of mesoporous ormeso-microporous silicate containing heteroatoms, having a randomlyconnected three-dimensional pore structure with tunable pore sizes. Itoffers a new, cost-effective process to synthesize the mesoporoussilicate without any surfactant involved. It provides new diversecatalytic materials. And it provides the processes to apply thecomposition in catalysis and separation.

Various features of the invention are illustrated by the Examples givenbelow. X-ray powder diffraction patterns (XRD) of the resultingmaterials were recorded using CuK_(a) radiation on a Philips PW 1840diffractometer equipped with a graphite monochromator. The samples werescanned in the range of 0.5-40° 2 θ with steps of 0.02°. Transmissionelectron microscopy (TEM) was performed using a Philips CM30T electronmicroscope with a LaB6 filament as the source of electrons operated at300 kV. Nitrogen sorption isotherms were measured on the QuantachromeAutosorb-6B at 77 K. Mesoporosity was calculated using the Barrett,Joyner and Halenda (BHJ) method. All composition parts are by weightunless indicated otherwise.

EXAMPLE 1

This example shows how to incorporate aluminum into silica withoutheating in an autoclave before calcination.

First, 1 part aluminum isopropoxide (Al(iso-OC₃H₆)₃) was added into 26parts of an aqueous solution of tetraethylammonium hydroxide (TEAOH,35%) while stirring. After dissolution, 38 parts of triethanolamine(TEA) together with 8 parts of water were added into the above solutionunder stirring. Then, 26 parts of tetraethyl orthosilicate (TEOS) wereadded under vigorous stirring. A clear solution was obtained. Thestirring was continued for 1 hour, and then the synthesis mixture wasaged at room temperature overnight and dried at 98° C. in air for 24hours. Finally, the synthesis mixture was calcined at 570° C. for 10hours in air with a ramp rate of 1° C./min.

FIG. 1 shows its XRD pattern with an intensive reflection at about 1.1°in 2 θ, indicating the characteristic of a mesoporous material. Inaddition, the absence of resolved peaks for alumina implies that nobulky alumina phase formed. FIG. 2 presents an image of transmissionelectron microscopy (TEM), showing a randomly connected mesoporousstructure. Elemental analysis showed it to have a Si/Al ratio of about24.8, which is consistent with the ratio of the initial synthesismixture of 25. Nitrogen adsorption revealed a surface area of 983 m²/g,a total pore volume of 1.27 cm³/g and a narrow mesopore distributioncentered at 4.2 nm, shown in FIG. 3.

EXAMPLE 2

This example demonstrates the incorporation of heteroatoms with heatingin an autoclave before calcination. 3.3 Parts of aluminum isopropoxidewere added into a bottle with 42 parts of TEOS and stirred for an hour.A mixture of 7.6 parts of TEA and 25.8 parts of water were added intothe mixture of TEOS and Al(iso-OC₃H₆)₃ under stirring. After 2 hoursstirring, 21 parts of TEAOH were drop-wise added into the above mixtureand a thick gel formed. The gel was dried in an oven at 98° C. for 22hours and then transferred into an autoclave at 190° C. for 16 hours.Finally the gel was calcined at 600° C. for 10 hours in air.

FIG. 4 shows its XRD pattern with an intensive reflection at a low anglein 2 θ, indicating the characteristic of mesoporous material. Elementalanalysis showed its Si/Al ratio of about 24.5, consistent with the ratioof initial synthesis mixture was 25. Nitrogen adsorption revealed asurface area of 799 m²/g, a total pore volume of 1.24 cm³/g and a narrowmesopore distribution centered at 4.5 nm.

EXAMPLE 3A

This demonstrates the incorporation of aluminum and its stability of thecomposition. 3 Parts of aluminum isopropoxide were added into a bottlewith 38.8 parts of TEOS and stirred for 1.5 hours. A mixture of 23 partsof TEA and 21 parts of water was added into the above mixture understirring. After 2 hours stirring, 23 parts of TEAOH were drop-wise addedinto the above mixture and after 0.5 hours stirring it turned into aclear solution. The solution was dried in an oven at 100° C. for 4 daysand then transferred into an autoclave at 190° C. for 7.5 days. Finallyit was calcined at 600° C. for 10 hours with a ramp rate of 1° C./min inair.

Elemental analysis showed the Si/Al ratio to be 99.2. FIG. 5 shows itsXRD pattern with an intensive peak. Nitrogen adsorption shows a narrowpore size distribution centered at 17 nm, as presented in FIG. 6, whichexhibited a surface area of about 385 m²/g, and a pore volume of about1.32 cm³/g.

EXAMPLE 3B

The material obtained in Example 3A was boiled in water for 17 hours,but its XRD pattern, seen in FIG. 5, still shows an intensive peak,similar to the original material. It indicates that this composition hashigh hydrothermal stability compared to other mesoporous materials.

EXAMPLE 3C

The material obtained in Example 3A was calcined at 900° C. in air, butits XRD pattern (FIG. 5) still shows an intensive peak, indicating thatthe mesoporous structure was preserved. This result indicates that thiscomposition has high thermal stability up to 900° C.

EXAMPLE 4

This is an example to use inorganic heteroatom sources to incorporatealuminum into silica. 7.2 Parts of aluminum nitrate nonahydrate weredissolved into 20 parts of water. Then, 61.4 parts of TEOS were addedand stirred for 0.5 hours. Another mixture with 56.3 parts oftetraethylene glycol and 24 parts of water were added into the abovemixture under stirring. After 1 hour stirring, 49 parts of aqueoussolution of tetraethylammonium hydroxide (TEAOH, 35 wt %) were added andafter 0.5 hours stirring the final mixture turned into a thick gel. Thegel was dried in an oven at 100° C. overnight and then transferred intoan autoclave at 180° C. for 3 hours. Finally, it was calcined at 600° C.for 10 hours with a ramp rate of 1° C./min in air.

Elemental analysis showed the Si/Al ratio of 15.3. Its XRD patternshowed an intensive peak at about 1 degree in 2 θ. Nitrogen adsorptionrevealed a narrow pore size distribution centered at 4.5 nm, a specificsurface area of about 786 m²/g, and a total pore volume of about 1.02cm³/g.

EXAMPLE 5

This illustrates the incorporation of vanadium into silica. 1 Part ofvanadium (IV) acetylacetonate was added into a bottle with 41 parts ofTEOS and stirred for 2 hours. A mixture of 30 parts of TEA and 25 partsof water were added into the above mixture under stirring. After 2 hoursstirring, 20 parts of TEAOH was drop-wise added into the above mixtureand after 0.5 hours stirring it turned into a hard gel. The gel was agedat room temperature for 24 hours and dried in an oven at 100° C.overnight and then calcined at 700° C. for 10 hours in air and finallyturned into orange powder.

Elemental analysis showed the Si/V ratio to be 50.5. FIG. 7 shows itsXRD pattern with an intensive peak for mesostructure and without anypeaks from vanadium oxide phases. Nitrogen adsorption showed a narrowpore size distribution centered at 4.1 nm, a specific surface area ofabout 835 m²/g, and a pore volume of about 0.91 cm³/g.

EXAMPLE 6

Here, titanium incorporation is demonstrated. 1 Part of titanium(IV)butoxide was added into a bottle with 31 parts of TEOS and stirred for 2hours. A mixture of 22.5 parts of TEA and 17 parts of water were addedinto the above mixture under stirring. After 1 hour stirring, 18.5 partsof TEAOH were drop-wise added into the above mixture and after 0.5 hoursstirring it turned into a thick gel. The gel was aged at roomtemperature for 22 hours and dried in an oven at 98° C. overnight andthen calcined at 700° C. for 10 hours in air and finally turned intowhite powder.

Elemental analysis showed the Si/Ti ratio to be 49.6. FIG. 8 shows itsXRD pattern with an intensive peak for meso-structure and no resolvedpeak for titanium oxide. Nitrogen sorption isotherms are shown in FIG.9, which revealed pore size distribution centered at 4.7 nm, shown inFIG. 10, a specific surface area of about 917 m²/g, and a total porevolume of about 0.84 cm³/g.

EXAMPLES 7-9

Here is a demonstration of the incorporation of three differentheteroatoms. 42 Parts of tetraethyl orthosilicate (TEOS) were mixed with30 parts of triethanolamine (TEA) for 1 hour to get mixture I. MixtureII was prepared by dissolving heteroatom sources into 22 parts of water.1 Part of gallium nitrate, 0.54 parts of zinc chloride and 0.9 parts oftin chloride were used for Examples 7, 8 and 9, respectively. Mixture IIwas drop-wise added into the mixture I under stirring. After thecombined mixtures I and II were stirred for 0.5 hours, 24.5 parts oftetraethylammonium hydroxide were drop-wise added while stirring. Afterbeing stirred for 2 hours, the three mixtures were each observed to beclear solutions and finally 0.5 g of ammonium hydroxide (27-30 wt %) wasadded. After being stirred for another 2 hours, the mixtures werestatically aged overnight. The mixtures were dried at 98° C. for 24hours and each turned into dried gel. The dried gels were charged intoautoclave at 180° C. for 2.5 hours and finally were calcined at 600° C.in air for 10 hours.

FIG. 11 shows XRD patterns of gallium, zinc and tin-containing silicatesprepared in Examples 7, 8 and 9, respectively. Table 1 presents themesoporosity and chemical composition of three materials. TABLE 1Mesoporosity of gallium-, zinc- and tin-containing silicates in Examples7, 8 and 9, respectively M content D_(p)* S_(BET)* V_(total)* ExampleHeteroatom M (wt %) (nm) (m²/g) (cm³/g) 7 Ga 1.3 4 830 0.71 8 Zn 1.9 5690 0.69 9 Sn 3.3 4.5 780 0.67*D_(p) stands for pore diameter,S_(BET) for specific surface area,V_(total) for total pore volume.

EXAMPLE 10

This example demonstrates the simultaneous incorporation of two types ofheteroatoms into silica. First, 2.7 parts of aluminum isopropoxide weremixed with 0.86 parts of vanadium (IV) acetylacetonate and 34 parts oftetraethyl orthosilicate (TEOS) to get the first mixture. The secondmixture contained 34 parts of TEA and 21 parts of water. Then the secondmixture was drop-wise added into the first mixture under stirring. Afterstirred for 1.5 hours, 16.8 parts of tetraethylammonium hydroxide weredrop-wise added while stirring. The synthesis mixture turned into athick gel. The gel was statically aged at room temperature overnight,dried at 100° C. for 42 hours and then heated in an autoclave at 180° C.for 3 days. Finally, it was calcined at 650° C. in air for 10 hours.

FIG. 12 shows the XRD pattern of the aluminum and vanadium-containingsilicate. Nitrogen adsorption revealed that it had a narrow pore sizedistribution around II nm (shown in FIG. 13), a surface area of about433 m²/g and total pore volume of about 1.25 cm³/g. Elemental analysisshowed that Si/Al=13.5 and Si/V=49.1.

EXAMPLE 11

This example demonstrates the preparation of Fe-containing mesoporoussilicate. One part of iron (III) nitrate was dissolved in 5 parts ofdeionized water and then added to 27.4 parts of tetraethyl orthosilicate(TEOS) and stirred for 1 hour. Another solution consisting of 19.8 partsof triethanolamine (TEA) and 30.4 parts of deionized water wereintroduced drop-wise into the first mixture. After another 1 h ofstirring, 16.2 parts of tetraethylammonium hydroxide (TEAOH) weredrop-wise added to the mixture. The final homogeneous pale yellowsolution was aged at room temperature for 24 hours, dried at 100° C. for24 hours, and finally calcined at 650° C. for 10 hours to get a paleyellow powder.

FIG. 14 shows the XRD pattern with one intensive peak at a low angle ofabout 0.5˜2.2°, representing the meso-structural characteristics.Elemental analysis showed the atomic ratio of Si/Fe was 48.8. UV-Visiblespectroscopy (FIG. 15) showed a peak around 220 nm, representing thefour coordinated iron, and also a shoulder ranged from 250˜350 nm,representing the octahedral coordination of iron in the silica matrix.N₂ adsorption measurements revealed the BET surface area of about 630m²/g, the average mesopore diameter of about 4.8 nm (cf. FIG. 16), andthe total pore volume of about 1.24 cm³/g.

EXAMPLE 12

The procedure of making Fe-containing silicate is similar to that inExample 11; however, only 0.52 part of iron (III) nitrate was used.After calcination, the elemental analysis showed that the powder has aSi/Fe atomic ratio of 98.6. Nitrogen adsorption showed a specificsurface area of 580 m²/g, an average pore diameter of 5.96 nm, and apore volume 1.82 cm³/g.

EXAMPLE 13

This demonstrates the preparation of Cr-containing silicate. 1.2 Partsof chromium nitrate nonahydrate were dissolved in 5 parts of deionizedwater and then added to 26.3 parts of tetraethyl orthosilicate (TEOS)and stirred for 1 hour. Another solution consists of 19 parts oftriethanolamine (TEA) and 22.2 parts of deionized water were introduceddrop-wise into the above solution. After another 1 hour of stirring,26.2 parts of tetraethylammonium hydroxide (TEAOH) were added drop-wiseto the mixture. The final homogeneous pale green solution was aged atroom temperature for 24 hours, dried at 100° C. for 24 hours, andfinally calcined at 650° C. for 10 hours to get a yellowish orangepowder containing chromium.

FIG. 17 shows the XRD pattern with one intensive peak at a low angle ofabout 0.5˜2.2° representing the meso-structural characteristics.UV-Visible spectroscopy (FIG. 18) showed two distinguishing peaks around220 and 390 nm, representing the four coordinated chromium, and also ashoulder around 480 nm representing the octahedral coordination ofpolychromate (—Cr—O—Cr—)_(n) in the silica matrix. N₂ adsorptionmeasurements revealed the BET surface area of about 565 m²/g, theaverage mesopore diameter of 1.96 nm (cf. FIG. 19), and the total porevolume of about 1.54 cm³/g.

EXAMPLE 14

The procedure of making Cr-mesoporous silicate is similar to that inExample 13; however, 1.31 parts of chromium nitrate were used. Aftercalcination, the elemental analysis showed that the powder has a Si/Cratomic ratio of 40.3. Nitrogen adsorption showed specific surface areaof 572 m²/g, pore diameter of 2.35 nm and pore volume of 1.7 cm³/g.

EXAMPLE 15

The preparation of the composition containing Mo is demonstrated here.1.6 parts of ammonium heptamolybdate tetrahydrate solution[(NH₄)₆Mo₇O₂₄.4H₂O] were dissolved in 5 parts of deionized water andthen added to 27.1 parts of tetraethyl orthosilicate (TEOS) and stirredfor 1 hour. Another solution consists of 19.6 parts of triethanolamine(TEA) and 30.4 parts of deionized water were introduced drop-wise intothe above solution. After another 1 hour of stirring, 16.1 parts oftetraethylammonium hydroxide (TEAOH) were added drop-wise to themixture. The final homogeneous pale yellow solution was aged at roomtemperature for 24 hours, dried at 100° C. for 24 hours, and finallycalcined at 650° C. for 10 hours to get a white powder.

FIG. 20 shows the XRD pattern with one intensive peak at a low angle ofabout 0.5˜2.2°, representing the meso-structural characteristics.UV-Visible spectroscopy (FIG. 21) shows a peak around 220 nmrepresenting four-coordinated molybdenum in the silica matrix. N₂adsorption measurements revealed the BET surface area of about 500 m²/g,the average mesopore diameter of about 8.91 nm (cf. FIG. 22), and thetotal pore volume of about 1.31 cm³/g.

EXAMPLE 16

The procedure of making Mo-mesoporous silicate is similar to that inExample 15; however, 3.9 parts of ammonium heptamolybdate tetrahydratesolution [(NH₄)₆Mo₇O₂₄.4H₂O] were used. After calcining, the elementalanalysis showed that the powder has a Si/Mo atomic ratio of 39.8.Nitrogen adsorption indicated a specific surface area of 565 m²/g, anaverage pore diameter of 3.93 nm, and pore volume of 0.98 cm³/g.

EXAMPLE 17

Simultaneous incorporation of both Ni and Mo into a mesoporous materialis demonstrated. First, 7.7 parts of nickel (II) nitrate hexahydrate and32 parts of ammonium heptamolybdate tetrahydrate were dissolved into 54parts of water under stirring. Then, 67 parts of tetraethylorthosilicate (TEOS) were added into the above solution under vigorousstirring. After stirring for 1.5 hours, 40 parts of tetraethylammoniumhydroxide (TEAOH) were drop-wise added while stirring. The synthesismixture turned into a thick gel. The gel was statically aged at roomtemperature overnight, dried at 100° C. for 24 hours and then heated inan autoclave at 180° C. for 3 hours. Finally, the synthesis mixture wascalcined at 600° C. in air for 10 hours.

The XRD pattern of the final powder shows an intensity peak at around1.1 degree 2 θ, indicating the characteristics of mesoporous material.Nitrogen adsorption reveals that it has a narrow pore size distributionaround 2.3 nm, a surface area of about 633 m²/g and total pore volume ofabout 0.86 cm³/g. Elemental analysis shows the final powder contained6.1 wt % of Ni and 10.5 wt % of Mo.

EXAMPLE 18

This example demonstrates simultaneous incorporation of both Ni and Winto a mesoporous material. First, 5.8 parts of nickel (II) nitratehexahydrate and 35 parts of ammonium metatungstate hydrate weredissolved into 42.3 parts of water under stirring. Then 50.5 parts oftetraethyl orthosilicate (TEOS) were added into the above solution undervigorous stirring. After stirring for 1.5 hours, 30.0 parts oftetraethylammonium hydroxide were drop-wise added while stirring. Thesynthesis mixture turned into a thick gel. The gel was statically agedat room temperature overnight, dried at 100° C. for 24 hours and thenheated in an autoclave at 180° C. for 3 hours. Finally, it was calcinedat 600° C. in air for 10 hours.

The XRD pattern of the final powder shows an intensity peak at around1.0 degree 2 θ, indicating the characteristics of mesoporous material.Nitrogen adsorption reveals that it has a narrow pore size distributionaround 2.4 nm, a surface area of about 649 m²/g and total pore volume ofabout 0.81 cm³/g. Elemental analysis shows the final powder contained6.4 wt % of Ni and 12.0 wt % of W.

EXAMPLE 19

The preparation of a palladium-containing catalyst was demonstrated. 65Parts of the material in Example 1 was mixed with 35 parts alumina andwater is added to this mixture to allow the resulting catalyst to beextruded. The catalyst was calcined at 480° C. in 5 v/v/min nitrogen for6 hours followed by the replacement of the nitrogen flow with 5 v/v/minof air. The calcining was completed by raising the temperature to 540C°, maintaining that temperature for 12 hours. Palladium wasincorporated by impregnation with an aqueous solution of a palladiumtetraamine salt, Pd(NH₃)₄Cl₂. The extrudate was then dried at 120° C.overnight and calcined at 300° C. in air for 3 hours. The final catalysthas 0.81 wt. % of palladium, surface area of 630 m²/g, particle densityof 0.83 g/ml, and pore volume of 1.21 cm³/g.

EXAMPLE 20

Alkylation of naphthalene with 1-hexadecene was carried out in a flaskwith mechanical stirring. Catalysts of Examples 1, 2, and 3A were used.1 Part of catalyst was loaded in the flask and heated up to 200° C.under vacuum for 2 hours. After the catalyst was cooled down to 90-100°C. under nitrogen, a mixture consisting of 6.5 weight parts ofnaphthalene and 26 parts of 1-hexadecene was injected into the flaskunder stirring. The temperature was raised up to 200-205° C. and keptconstant. The reaction mixture was analyzed by gas chromatography withWAX 52 CB column. Reaction results using different catalysts aresummarized in Table 2. TABLE 2 Naphthalene alkylation with 1-hexadeceneover different catalysts Reaction Naphthalene time conversionSelectivity* Catalyst Composition (hr) (%) (%) Example 1 Si/Al = 24.8 425.6 57.6 Example 2 Si/Al = 24.5 4.5 27.3 56.7 Example 3A Si/Al = 99.2 419.6 65.3*The selectivity refers to the selectivity towards monoalkylatednaphthalene.

EXAMPLE 21

Friedel-Crafts alkylation of benzene with chlorobenzene was conducted ina flask with magnetic stirring. Catalysts of Examples 7, 9, 11 and 12were used. 1 Part of the catalyst was loaded in the flask and heated upto 180° C. under vacuum for 4 hours. After the catalyst was cooled downto 80° C. under nitrogen, a mixture consisting of 102 parts of benzeneand 8.2 parts of benzyl chloride were introduced into the flask. Thetemperature was constantly kept at 60° C. or 80° C. The reaction mixturewas analyzed by gas chromatography with WAX 52 CB column. Reactionresults using different catalysts are summarized in Table 3. TABLE 3Benzylation of benzene to produce diphenyl methane over differentcatalysts Reaction Tem- Con- Selec- time perature version tivityCatalyst Composition (min.) (° C.) (%) (%) Example 12 Si/Fe = 98.6 24060 86 100 Example 11 Si/Fe = 50.1 60 60 51 100 Example 11 Si/Fe = 50.1150 60 100 100 Example 11 Si/Fe = 50.1 60 80 97 100 Example 7 Si/Ga = 71240 60 64.9 100 Example 9 Si/Sn = 46 240 60 15.8 100

EXAMPLE 22

Selective oxidation of ethylbenzene to acetophenone was performed in aflask under nitrogen with stirring. Catalysts of Examples 13, 14 and 16were used. One part of the catalyst was activated at 180° C. for 4 hoursunder vacuum, and then the cooled down to 80° C. Then a mixtureconsisting of 100 parts of acetone, 82 parts of ethylbenzene and 9.5parts of tert-butyl hydroperoxide (TBHP) were introduced to the flaskunder stirring. The reaction mixture was analyzed by gas chromatographywith WAX 52 CB column. Reaction results over various catalysts aresummarized in Table 4. TABLE 4 Conversion of ethylbenzene toacetophenone over different catalysts. Gas Tem- Con- Selec- CatalystComposition Time flow perature version tivity Example Si/Cr = 130 480Dry N₂ 80 68.5 94.5 13 Example Si/Cr = 130 480 air 80 73.6 95.3 13Example Si/Cr = 130 480 air 60 54.7 99.3 13 Example Si/Cr = 40.3 480 air80 67.3 92.9 14 Example Si/Mo = 39.8 360 air 80 24.2 58.9 16

EXAMPLE 23

Oligomerization of 1-decene was performed in a stirred batch reactor.The catalyst of Example 2 was used. In the reactor 1 part of catalystwas activated by heating in nitrogen at 200° C. for 2 hours. 25 Parts of1-decene were added by syringe under nitrogen flow. The reaction wascarried out at 150° C. for 24 hours. After the reactor was cooled down,the product was analyzed by gas chromatography (GC) with a WAX 52 CBcolumn. For each test, mole % decene conversion and dimer selectivity ispresented in Table 5. TABLE 5 Oligomerization of 1-decene over differentcatalysts Catalyst Composition Time Temperature Conversion Example 2Si/Al = 24.5 4 150 12.6 Example 2 Si/Al = 24.5 24 150 25.8

EXAMPLE 24

Acylation of 2-methoxynaphthalene to 2-acetyl-6-methoxynaphthalene isperformed in a stirred batch reactor. The reactor with 16 parts ofcatalysts made in Example 2 is heated at 240° C. under vacuum for 2hours and then filled with dry nitrogen. After the reactor is cooleddown to 120° C., 250 parts of decalin (as a solvent), 31 parts of2-methoxynaphthalene, 42 parts of acetic anhydride and 10 parts ofn-tetradecane (as an internal standard) are injected into the reactor.After 6 hours reaction, the reactor mixture is analyzed by GC with a WAX52 CB column, and it is found that the conversion of2-methoxynaphthalene reaches 36.5% with 100% selectivity to2-acetyl-6-methoxynaphthalene.

EXAMPLE 25

Oxidation of cyclohexanol to cyclohexanone was carried out in a stirredbatch reactor. The reactor with 1 part of catalysts is heated at 180° C.under vacuum for 4 hours and then filled with dry nitrogen. After cooleddown to 55° C., 100 parts of acetone, 10 part of tert-butylhydroperoxide (TBHP) and 7.5 parts of cyclohexanol were introduced theflask; and the reaction temperature was kept at 55° C. After 5 hoursreaction, the reactor mixture is analyzed by GC with WAX 52 CB column;and the performance of different catalysts was summarized in Table 6.TABLE 6 Oxidation of cyclohexanol to cyclohexanone over variouscatalysts Tem- perature Time Conversion Selectivity Catalyst Composition(° C.) (hr) (%) (%) Example 15 Si/Mo = 97.9 55 5 79.4 95 Example 16Si/Mo = 39.8 55 5 84.6 93

EXAMPLE 26

The material of Example 17 was evaluated for upgrading Paraho shale oilat 68 bar H₂ and LHSV of 2.0. Reaction temperature varied from 260 to400° C. The shale oil properties are given in Table 7. Productproperties after upgrading are summarized in Table 8. TABLE 7 Propertiesof Paraho Shale Oil Sample Gravity, ° API 21.7 Hydrogen, wt % 11.49Nitrogen, wt % 2.2 Sulfur, wt % 0.69 Arsenic, ppmw 37 Iron, ppmw 27Nickel, ppmw 2.4 Bromine Number 45 Avg. Molecular Weight 307 C═C bondsper molecule 0.85 Simulated Distillation D2887 (° C.)  5% 239 30% 37350% 432 70% 491 95% —

TABLE 8 Guard Chamber Processing of Shale Oil - Product Properties Tem-perature Bromine Iron Nickel Arsenic Sulfur Nitrogen (° C.) No. (ppmw)(ppmw) (wt. %) (ppmw) (ppmw) 260 0.7 3.5 1.95 5.3 0.63 1.98 290 <0.1 2.61.85 4.2 0.57 1.89 315 <0.1 2.0 1.61 3.1 0.48 1.78 370 <0.1 0.2 1.3 <0.10.25 1.40 400 <0.1 <0.1 0.1 <0.1 <0.1 1.18The evaluation shows that the catalytic material of Example 17 is veryactive for olefin saturation, removal of iron and nickel,denitrogenation, and desulfurization. It is also very active for arsenicremoval.

EXAMPLE 27

Selective lube hydrocracking is performed on a Ni- and W-containingmesoporous material of Example 18 above. The feedstock consists of aheavy neutral distillate having the properties given in Table 9 below,together with the properties of the oil after solvent dewaxing to −18°C. pour point (ASTM D-97 or equivalent such as Autopour). After solventdewaxing, the nitrogen content is 1500 ppm; and the distillate viscosityindex (“VI”) is 53. In lube hydrocracking, the objective is to increasethe unconverted material's VI level to the 95-100 range while maximizinglube yield. TABLE 9 Heavy Neutral Distillate Properties Hydrogen, wt %12.83 Nitrogen, ppm 1500 Basic Nitrogen, ppm 466 Sulfur, wt % 0.72 APIGravity 22.0 KV @ 100° C., cSt 18.52 Composition, wt % Paraffins 18.3Naphthenes 32.2 Aromatics 49.5 Simulated Distillation wt % ° C. IBP 4055% 452 10% 471 95% 586 Solvent Dewaxed Oil Properties KV @ 100° C., cSt20.1 Viscosity Index (VI) 53 Pour Point, ° C. 0 Lube Yield, wt % 87

The distillate is processed at temperatures from 385 to 401° C., 138 barhydrogen pressure, hydrogen circulation of 7500 SCF/B feed and 0.55 to0.61 LHSV. The data from these experimental runs are summarized in Table10 below: TABLE 10 Temp., ° C. 125 739 754 Pressure, bar 138 138 138LHSV 0.61 0.54 0.55 343° C.+ conv., wt % 22.9 37.6 47.3 Lube PropertiesKV @ 100° C., cSt 11.05 7.89 5.45 SUS @ 100° F. 695 398 201 VI 86.2110.2 126.3 Pour Point, ° C. 13 28 29 Lube Yield, wt % 71.5 60.6 51.3

The catalytic material is selective for upgrading the heavy neutraldistillate from a raw distillate VI of 53 to a 105 VI product at a(undewaxed) lube yield of 65 wt %.

EXAMPLE 28

This example demonstrates the preparation of FCC catalyst using thecomposition of this invention and compares its cracking results withthat of a catalyst using MCM-41. Catalyst preparation was as follows:

About 35 wt % of the composition of Example 4 in a silica-alumina-claymatrix was prepared. 130 parts of the composition of Example 4 wereball-milled for 14 hours in 230 ml H₂O. The product was rinsed from themill with 52.5 ml of H₂O. A slurry was prepared containing 827 g of H₂O,33.5 parts of kaolin clay (Georgia Kaolin Kaopaque), and 175.4 parts ofhydrous silica (Philadelphia Quartz N-brand). The slurry was stirred and16.4 parts of H₂SO₄ (96.7%) were added over a 30 minute period. 22.9Parts of Al₂(SO₄)₃.16H₂O dissolved in 92.2 of H₂O were added dropwise.396 Parts of the ball-milled MCM-41 slurry (11.36% solids) were added tothe silica-alumina-clay slurry, and the mixture was vigorously stirredat 800 rpm for 30 minutes and then filtered.

The solid was re-slurried in H₂O and spray dried. The spray-driedproduct was slurried with H₂O and the fines floating on the slurry werediscarded. The remaining solid was exchanged with 1N NH₄NO₃ (5 ccNH₄NO₃/g of solid). The solid was washed with H₂O, filtered, and driedin an oven at 120° C.

A 50 g sample of this material was calcined at 540° C. for one hour inN₂ and 6 hours in air. The remainder of the oven-dried solid was steamedin 45% H₂O at 650° C. for 4 hours. Prior to admitting steam to thereactor, the sample was heated to 650° C. in N₂. Air was graduallyincreased over a ½ hour period while the N₂ flow rate was increased.After the ½ hour period steam was admitted for the 4-hour period.

For comparison, a FCC catalyst containing 35 wt % MCM-41 was prepared inthe same way as described above. The original MCM-41 had a surface areaof 980 m²/g, a pore size distribution centered around 2.5 nm, and a porevolume of 0.72 cm³/g. It contained 5.4 wt % Al₂O₃, similar to 5.3 wt. %in the material of Example 4. Properties of the steamed catalysts areshown in Table 11. TABLE 11 Comparison of the FCC catalyst containingthe composition of the invention and the one containing MCM-41 aftersteaming. Catalyst Invention Composition MCM-41 SiO₂, wt % 72.6 71.8Al₂O₃, wt % 13.8 13.7 Surface area, m²/g 462 307 Avg. particle size, μm86 92 Packed density, g/cc 0.65 0.43Catalytic Cracking Test

The two catalysts in Table 11 are evaluated for cracking Joliet SourHeavy Gas Oil (“JSHGO”) in a fixed-fluidized bed unit at 516° C. and oneminute on stream. The JSHGO used had the properties shown in Table 12.The catalyst-to-oil ratio is varied from 2.0 to 6.0 to examine a widerange of conversions. The yields are summarized in Table 13, given on aconstant coke (4.0 wt %) basis. TABLE 12 Properties of JSHGO sampleDensity, g/cc 0.8918 Aniline Pt., ° C. 80.8 Hydrogen, wt % 12.13 Sulfur,wt % 2.4 Nitrogen, wt % 0.41 Basic Nitrogen, ppm 382 Conradson Carbon,wt % 0.54 KV 100° C., cSt 8.50 KV 40° C., cSt N/A Bromine No. 8.7 R.I.21° C. 1.496 Pour Point, ° C. 90 Ni, ppm 0.34 V, ppm 0.39 Na, ppm 1.3Fe, ppm 0.3 Distillation Profile % Vol Distilled T° C.  5 314.  10 346 20 381  30 407  40 428  50 448  60 468  70 489  80 514  90 547 100 601% unrecovered 0

TABLE 13 Catalytic cracking comparison between the catalyst containingthe inventive composition and one containing MCM-41. Catalyst Theinvention MCM-41 DELTA Coke, wt % 4.0 4.0 Conversion, wt % 59.9 56.8 3.1C₅ + gasoline, wt % 39.7 37.2 2.5 RON 93 92 1 LFO, wt % 31.5 32.2 −0.7HFO, wt % 10.2 11.0 −0.8 C₄'s, vol % 14.7 13.3 1.4 Light gas, wt % 6.97.3 −0.4 H₂, wt % 0.03 0.04 −0.01 C₅'S, vol % 5.5 4.7 0.8

EXAMPLE 29

A medium pressure hydrocracked bottoms fraction was subjected tocatalytic dewaxing and hydroprocessing. The feed was processed incascade operation over fixed bed reactors. Eighty grams of HZSM-5dewaxing catalyst was loaded into a first reactor and 240 g of theinvention catalyst as described in Example 19 was loaded into the secondreactor. The feed is passed over both catalysts at 175 bar, 1.0 LHSVover the dewaxing catalyst, 0.33 LHSV over the hydroprocessing catalyst.The temperature in the first reactor was maintained at 307-321° C. togive a target pour point of −6.6° C. The properties of the bottomsfraction are described below in Table 14. TABLE 14 Heaviest 10% ofBottoms Properties at 45 wt. % 377° C.+ conversion Nitrogen, ppm 9 Mol.Weight 558 Pour Point, ° C. >120 KV @ 100° C., cSt 11.3 Composition, wt% Paraffins 42.1 Mononaphthenes 19.9 Polynaphthenes 21.2 Aromatics 16.8Simulated Distillation ° F. IBP/5 209/854 10/50 902/982

UV absorbance of the product was used to determine the aromatics in thelubricant base stock. The absorbance at 226 nm is a measure of the totalaromatics while the absorbance at 400 nm (×10³) is a measure of thepolynuclear aromatics. For comparative purposes over Pd/MCM-41,catalysts prepared in accordance with the procedure described in Example19 were also tested. The results of the runs are summarized in thefollowing Table 15. TABLE 15 Lube Hydrotreating at 274° C. Run 1 2 MetalPd Pd Support MCM-41 Example 1 Total aromatics, 226 nm 0.210 0.120Polynuclear aromatics, 1.30 0.78 400 nm (×10³)

Comparing the performance of the Pd/MCM-41 catalyst with the catalystcontaining Pd on the composition of this invention, it is apparent thatthe composition of this invention is much more effective in saturatingaromatics.

EXAMPLE 30

This example demonstrates using the composition of the invention as acatalyst for hydrotreating of a coal liquid. While the specificcoal-derived liquid exemplified here is a liquefaction product of theH-Coal process (using Illinois No. 6 coal as the starting material),other coal liquids (e.g. coal tar extracts, solvent refined coal, etc.)can be similarly upgraded. The catalyst sample was made in the same wayas described in Example 3A. However, the method included hydrothermaltreatment in an autoclave at 190° C. for a relatively short period oftime of 4 days. Nitrogen adsorption showed mesopores with a sizecentered at 11 nm with a surface area of about 630 m²/g. Elementalanalysis showed a Si/Al atomic ratio of about 99.6.

The material is further impregnated with an ammonium heptamolybdatesolution. Particularly, 45.12 parts of an aqueous solution containing6.38 parts of ammonium heptamolybdate is added to 40 parts of the abovematerial. The resulting wet material was dried at 120° C. and calcinedin air at 538° C. under conditions sufficient to decompose ammoniumheptamolybdate and generate MoO₃, thereby producing a molybdenumimpregnated material.

The molybdenum-impregnated material is then impregnated with a nickelnitrate solution. Particularly, 48.2 parts of an aqueous solutioncontaining 9.3 parts of Ni(NO₃)₂.6H₂O is added to themolybdenum-impregnated material. The resulting wet material is dried at121° C. and then calcined in air at 538° C. to decompose nickel nitrateand generate NiO, thereby producing a nickel and molybdenum impregnatedmaterial. Elemental analysis shows that the final material contains 15.0wt % of MoO₃ and 6.4 wt % of NiO.

For comparison, an MCM-41 material is used, which has a surface area of992 m²/g, a pore size distribution centered at 3.5 nm, and a pore volumeof 0.72 cm³/g. It is impregnated in the same way as described above andfinally contains 15.2 wt % of MoO₃ and 6.7 wt % of NiO.

Their activities for hydrotreating are evaluated using Illinois H-coalas feedstock. Table 16 shows the properties of the feedstock. TABLE 16(Properties of Illinois H-coal) Gravity, °API 25.8 Aniline Point, ° C.<−1.1 Molecular Weight 147 Viscosity, cSt at 38° C. 1.645 CCR, Wt. %0.29 Bromine No. 42 Carbon, Wt. % 86.96 Hydrogen, Wt. % 11.39 Sulfur,Wt. % 0.32 Oxygen, Wt. % 1.80 Total Nitrogen, Wt. % 0.46 Basic Nitrogen,Wt. % 0.30 Iron, ppm 22 Chloride, ppm 32 TBP Distillation, ° C. St/513/81 10/30 101/167 50 207 70/90 242/309 95/99 346/407

These two catalysts are presulfided for a period of 1 hour in a 500cm³/min flow of 10% H₂S in H₂ at 230° C. and a total pressure of 680kPa. Hydrotreating is conducted at a temperature of 350° C., a pressureof 6890 kPa, a hydrogen flow rate of 500 cm³/min, a liquid hour spacevelocity of 0.33. Table 17 shows the comparison of activity in terms ofdenitrogenation, Conradson Carbon Residue (CCR) reduction, anddesulfurization. TABLE 17 Comparison of hydrotreating activity CatalystThis invention MCM-41 catalyst Denitrogenation (%) 73 48 CCR reduction(%) 98 63 Desulfurization (%) 95 58

The catalyst of this invention shows much higher activity, whichpartially should be attributed to its unique pore structure. It hasrelatively large pores with three-dimensional connection, which canaccommodate and transport large molecules such as present in coalliquids.

EXAMPLE 31

This Example demonstrates the preparation of Fischer-Tropsch catalystand its catalytic performance. Twenty (20) parts of Al-containingmaterial made in Example 1 is dried at 200° C. for half an hour under N₂flow. It is then mixed thoroughly with 2 parts of CO₂(CO)₈ in a glovebox. This mixture of solids is placed into a tube furnace boat in asealed tube and removed from the glove box. Then it is heated in flowinghelium at 100° C. for 15 minutes, raised to 200° C. over 10 minutes,then heated at 200° C. in helium for half an hour. The final catalystcontains 16 wt. % Co.

The above catalyst is treated with hydrogen prior to test. It is placedin a small quartz crucible in a chamber and purged with nitrogen at8.5×10⁻⁶ Nm³/s at room temperature for 15 minutes. It is then heated at1° C./min to 100° C. under flowing hydrogen at 1.8×10⁻⁶ Nm³/s and heldat 100° C. for one hour. It is then heated at 1° C./min to 400° C. andheld at 400° C. for four hours under flowing hydrogen at 1.8×10⁻⁶ Nm³/s.The catalyst is cooled in hydrogen and purged with nitrogen before use.

A pressure vessel containing the catalyst and n-octane is heated at 225°C. under 69 bar of H₂:CO (2:1) and held at that temperature and pressurefor 1 hour. The reactor vessel is cooled in ice, vented, and an internalstandard of di-n-butylether is added. Hydrocarbons in the range ofC₁₁-C₄₀ are analyzed relative to the internal standard by GC.

A C₁₁ ⁺ Productivity (g C₁₁ ⁺/hour/kg catalyst) is calculated to be 234based on the integrated production of the C₁₁-C₄₀ hydrocarbons per kg ofcatalyst per hour. The logarithm of the weight fraction for each carbonnumber ln(Wn/n) is plotted as the ordinate vs. number of carbon atoms in(Wn/n) as the abscissa. From the slope, a value of alpha is obtained tobe 0.87.

While the above description contains many specifics, these specificsshould not be construed as limitations on the scope of the invention,but merely as exemplifications of preferred embodiments thereof. Thoseskilled in the art will envision many other possibilities within thescope and spirit of the invention as defined by the claims appendedhereto.

1-34. (canceled)
 35. A catalytic material comprising a substantiallymesoporous structure of silica containing at least 97% by volume ofpores having a pore size ranging from about 15 Å to about 300 Å andhaving a micropore volume of at least about 0.01 cc/g and having surfacearea of from 300 to about 1100 m²/g, and wherein the mesoporousstructure has incorporated therewith at least about 0.02% by weight ofat least one catalytically and/or chemically active heteroatom selectedfrom the group consisting of Al, Ti, V, Cr, Zn, Fe, Sn, Mo, Ga, Ni, Co,In, Zr, Mn, Cu, Mg, Pd, Ru, Pt, W and combinations thereof, saidcatalyst has an X-ray diffraction pattern with one peak at 0.3° to about3.50 at 2 θ.
 36. The catalytic material of claim 33 further comprising abinder, selected from a group of silica, alumina, clay and theircombination.